Oil cooler

ABSTRACT

An apparatus for transferring heat between a first fluid and second fluid in a motor vehicle includes a housing, a first header, a second header, and a plurality of heat exchange tubes. The housing defines a chamber and includes a first inlet, a second inlet, a first outlet, and a second outlet. The first and second headers separate a central portion of the chamber from a first and second header portion of the chamber, respectively. The first inlet and the first outlet are in fluid communication with the central portion. The second inlet is in communication with the first header portion. The second outlet is in fluid communication with the second header portion. Each of the plurality of heat exchange tubes passes through the central portion of the chamber and has a first end in fluid communication with the first header portion and a second end in fluid communication with the second header portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/681,376, filed on Aug. 9, 2012. The entire disclosure of the above application is incorporated herein by reference.

TECHNICAL FIELD

The present teachings generally relate to oil coolers for motor vehicles.

INTRODUCTION

This section provides background information related to the present disclosure which is not necessarily prior art.

Various designs of oil to air heat exchangers are known in the automotive industry. Also known are oil to water heat exchangers. Such heat exchangers are used in controlling and/or reducing engine and transmission oil temperatures.

Stacked plate coolers are popular for reducing or controlling engine oil temperatures. They can be placed in remote areas of the engine compartment but mostly are attached to the engine or transmission block or case to eliminate coolant or oil lines. In-tank coolers are also very popular for transmissions and engines. In-tank coolers are housed within the radiator side tanks.

While known oil coolers for motor vehicles have proven to be generally acceptable for their intended purpose, a continuous need for improvement remains in the relevant art.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

The present invention provides an oil to coolant heat exchanger that not only allows heat transfer from the hotter engine or transmission oil to the water but also provides for warming of the transmission and engine oil during initial start-ups during cold ambient conditions.

According to one particular aspect, the present disclosure provides an apparatus for transferring heat between a first fluid and second fluid in a motor vehicle. The apparatus includes a housing, a first header, a second header, and a plurality of heat exchange tubes. The housing defines a chamber and includes a first inlet, a second inlet, a first outlet, and a second outlet. The first header separates a central portion of the chamber from a first header portion of the chamber. The first inlet and the first outlet are in fluid communication with the central portion. The second inlet is in communication with the first header portion. The second header separates the central portion of the chamber from a second header portion of the chamber. The second outlet is in fluid communication with the second header portion. Each of the plurality of heat exchange tubes passes through the central portion of the chamber and has a first end in fluid communication with the first header portion, a second end in fluid communication with the second header portion. The tubes are oriented parallel to one another and have a wavy configuration extending through the central portion.

According to another particular aspect, the present disclosure provides an apparatus for transferring heat between a first fluid and second fluid in a motor vehicle. The apparatus includes a housing, a first header, a second header and a plurality of heat exchange tubes. The housing defines a chamber and includes a first inlet, a second inlet, a first outlet, and a second outlet. The first header separates a central portion of the chamber from a first header portion of the chamber. The first inlet and the first outlet are in fluid communication with the central portion. The second inlet is in communication with the first header portion. The second header separates the central portion of the chamber from a second header portion of the chamber. The second outlet is in fluid communication with the second header portion. Each of the plurality of heat exchange tubes passes through the central portion of the chamber and has a first end in fluid communication with the first header portion, a second end in fluid communication with the second header portion. Each tube is defined in part by a pair of spaced apart sidewalls. Each tube includes a plurality of internal webs extending between the respective spaced apart sidewalls.

According to yet another particular aspect, the present disclosure provides an apparatus for transferring heat between a first fluid and second fluid in a motor vehicle. The apparatus includes a housing, a first header, a second header and a plurality of heat exchange tubes. The housing defines a chamber and includes a first inlet, a second inlet, a first outlet, and a second outlet. The first header separates a central portion of the chamber from a first header portion of the chamber. The first inlet and the first outlet are in fluid communication with the central portion. The second inlet is in communication with the first header portion. The second header separates the central portion of the chamber from a second header portion of the chamber. The second outlet is in fluid communication with the second header portion. Each tube is defined in part by a pair of spaced apart sidewalls. Each tube includes a plurality of internal webs extending between the respective spaced apart sidewalls. Each tube also includes a plurality of dimples. Each dimple is formed directly over one of the webs.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1 is perspective view of an oil cooler in accordance with the present teachings.

FIG. 2 is end view of the oil cooler of FIG. 1.

FIG. 3 is a side view of the oil cooler of FIG. 1.

FIG. 4 is another perspective view of the oil cooler of FIG. 1, the oil cooler shown in cross section taken along the line 4-4 of FIG. 1.

FIG. 5 is a cross-sectional view taken along the line 5-5 of FIG. 1.

FIG. 6 is a cross-sectional view taken along the line 6-6 of FIG. 1.

FIG. 7 is a cross-sectional view of a first preferred tube of the present teachings.

FIG. 8 is a side view of a second preferred tube of the present teachings.

FIG. 9 is a cross-sectional view taken along the line 9-9 of FIG. 7.

DESCRIPTION OF VARIOUS ASPECTS

Example embodiments will now be described more fully with reference to the accompanying drawings.

Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

With general reference to FIGS. 1-6 of the drawings, an oil cooler in accordance with the present teachings is illustrated and generally identifies at reference character 10. The oil cooler 10 generally includes a housing 12 defining a chamber 14. As illustrated, the housing 12 is generally rectangular in shape, includes four sidewalls 16 and first and second endwalls 18 and 20, and is elongated along an axis X. It will be understood, however, that the oil cooler 10 may be alternatively shaped within the scope of the present teachings.

The housing 12 may be formed of aluminum or other suitable material. As illustrated, the housing 12 may be integrally formed to include a plurality of ribs or fins 22 extending from each of the sidewalls 16. The ribs 22 may increase the external surface area of the housing 12 and thereby improve the heat transfer characteristics of the housing 12.

The oil cooler 10 is illustrated to generally include a first inlet or coolant inlet 24, a first outlet or coolant outlet 26, a second inlet or oil inlet 28, and a second outlet or oil outlet 30. In the embodiment illustrated, the first inlet 24 and first outlet 26 extend from one of the sidewalls 16 and may be in fluid communication with a heater core (not shown) for receiving a fluid (i.e., coolant) from the heater core. In the embodiment illustrated, the fluid may be propylene glycol or similar fluid that prevents freezing at ambient temperatures below 32 degrees Fahrenheit and also has a relatively high boiling point. Further in the embodiment illustrated, the second inlet 28 and second outlet 30 may extend from the first and second end walls 18, 20, respectively, and may be in fluid communication with an engine (not shown) for receiving a fluid (i.e., engine oil) from the engine. Alternatively or additionally, the second inlet 28 and second outlet 30 may be in fluid communication with a transmission (not shown) for receiving a transmission oil.

The oil cooler 10 is further illustrated to include first and second partitions or headers 32 and 34. The first and second headers 32 and 34 divide the chamber 14 of the oil cooler 10 into a central portion or coolant portion 14A and first and second header portions 14B and 14C (see FIG. 6). The central portion 14A is in fluid communication with the first inlet 24 and the first outlet 26. The central portion 14A is filled with coolant and a fluid path is established between the first inlet 24 and the first outlet 26 for routing coolant through the oil cooler 10.

The second inlet 28 and the second outlet 30 are in fluid communication with the first and second header portions 14A and 14B, respectively. The first and second headers 32 and 34 prevent fluid communication between the central portion 14A of the chamber and the second inlet 28 and second outlet 30, respectively.

A heat absorbing arrangement 36 may be disposed in the central portion 14A of the chamber 14. The heat absorbing arrangement 36 may include a plurality of elongated tubes 38 constructed of aluminum or other suitable metal for transferring heat to or from the coolant. In the embodiment illustrated the tubes 38 are generally rectangular in cross section and elongated in a horizontal direction. It will be understood, however, that the tubes 38 may be alternatively oriented within the scope of the present teachings. A first end 40 of each of the tubes 38 may be in fluid communication with the second inlet 28 and sealed with the first header 32. A second end 42 of each of the tubes 38 may be in fluid communication with the second outlet 30 and sealed with the second header 34. The first and second ends 40 and 42 of each tube 38 may be brazed to the first and second headers 32 and 34, respectively.

With particular reference to FIG. 6, the tubes 30 may have a generally waved or corrugated construction extending from the first end 40 to the second end 42. It will be appreciated, however, that the tubes 38 may take any suitable shape within the scope of the present teachings. The waved construction may be preferred to provide turbulence to the oil and thereby increase heat transfer to the coolant. The wave configuration may also extend the effective length of the fluid paths defined by the tubes 38.

Turning to FIG. 7, a preferred construction of a tube 38 of the present teachings is shown in cross section. The tube 38 is illustrated to include a plurality of webs 44. The webs 44 are integrally extended with the tube 38, are oriented generally parallel to one another, and horizontally extend between opposing walls 46 of the tube 38.

In the particular embodiment illustrated, the tubes 38 may have a height H of approximately 34 mm and a width W of approximately 2-8 mm. In this particular embodiment, the webs 44 may be spaced apart from one another by about 2.5 mm. It will be understood, however, that the particular dimensions are merely exemplary and may be altered within the scope of the present teachings.

Each tube 38 importantly defines a closed vessel for the transfer of fluid from the first header 32 to the second header 34. In other words, the complete path between the headers 32 and 34 is through closed vessels. The plurality of webs 44 allow the wall thickness of the tubes 38 to be significantly reduced to thereby reduce the required amount of material without jeopardizing performance of the tubes 38. In the embodiment described, the tubes 38 are designed to withstand a rupture pressure of 500 psi.

Turning to FIGS. 8 and 9, another preferred construction of a tube 138 of the present teachings is illustrated. FIG. 8 is a side view of one of the tubes 138. FIG. 9 is a cross-sectional view taken along the line 9-9 of FIG. 8 and similar to the cross-sectional view of FIG. 7. The tube 138 differs from the tube 38 in that it incorporates a plurality of dimples 50.

As illustrated best in FIG. 9, the dimples 50 may be formed as concave depressions in the surface of one of the tube sidewalls 46. The dimples 50 may be formed directly over alternating webs 40. Forming of the dimples 50 directly over one of the webs 40 allows for the formation of significantly larger dimples without any metal tearing. Each dimple 50 extends substantially to webs 40 adjacent to the central web 40 on either side. Fluid flows through the tube 38 in generally triangular sections 52 thereof. Each triangular section 52 is defined by a dimple 50, one of the central webs 40, and an adjacent one of the webs 40.

It will be understood that the dimples 50 and the webs 40 may be used with or without the wavy configuration shown in FIG. 6.

Operation of the oil cooler 10 will now be described in detail. During one mode of operation (e.g., a cold start of a vehicle) low temperature oil may enter the second inlet 28 of the housing 12 and flow through the tubes 38 to the second outlet 30 of the housing. High temperature coolant may enter the first inlet 24 of the housing 12 and flow around the tubes 38 to the first outlet 26. Heat may be transferred from the high temperature coolant to the low temperature oil through the walls of the tubes 38. The heated oil may then be pumped to the engine and/or the transmission, where heat may be transferred to the components thereof in order to improve the operating efficiency of the engine and transmission.

According to one particular application, the heat may be obtained from the exhaust of the motor vehicle. Specific embodiments for capturing heat from the exhaust of the vehicle are shown and described in a commonly owned application filed on 9 Aug. 2012 entitled SYSTEM, APPARATUS AND METHOD FOR QUICK WARM-UP and assigned U.S. Ser. No. 13/570,725. This application is incorporated by reference as if fully set forth herein.

During another mode of operation (e.g., operation or start-up of a warm vehicle), high temperature oil may similarly enter the second inlet 28 of the housing 12 and flow through the tubes 38 to the second outlet 30 of the housing 12. Low temperature coolant may enter the first inlet 24 of the housing 12 and flow around the tubes 38 to the first outlet 26. Heat may be transferred from the high temperature oil to the low temperature coolant through the walls of the tubes 38. The heated coolant may then be pumped to the heater core, where heat may be transferred to the passenger compartment of the vehicle to improve the operating comfort of the vehicle.

The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention. 

What is claimed is:
 1. An apparatus for transferring heat between a first fluid and second fluid in a motor vehicle, the apparatus comprising: a housing defining a chamber, the housing having a first inlet, a second inlet, a first outlet, and a second outlet; a first header separating a central portion of the chamber from a first header portion of the chamber, the first inlet and the first outlet in fluid communication with the central portion, the second inlet in communication with the first header portion; a second header separating the central portion of the chamber from a second header portion of the chamber, the second outlet in fluid communication with the second header portion; and a plurality of heat exchange tubes passing through the central portion of the chamber, each of the tubes having a first end in fluid communication with the first header portion, a second end in fluid communication with the second header portion; wherein the tubes are oriented parallel to one another and have a wavy configuration extending through the central portion.
 2. The apparatus of claim 1, wherein each tube of the plurality of tubes is generally rectangular in shape.
 3. The apparatus of claim 2, wherein each tube of the plurality of rubes includes a plurality of internal webs interconnecting first and second sidewalls of the respective tube.
 4. The apparatus of claim 1, wherein the tubes are integrally extended to include the plurality of webs.
 5. The apparatus of claim 1, wherein each tube of the plurality of tubes has a height significantly greater than a width and each tube includes a plurality of internal webs extending across the width.
 6. The apparatus of claim 1, wherein the first end of each tube is brazed to the first header and the second end of each tube is brazed to the second header.
 7. The apparatus of claim 6, wherein each tube of the plurality of tubes defines a closed vessel for the transfer of fluid between the first and second header portions.
 8. The apparatus of claim 1, wherein the first fluid is coolant and the second fluid is oil.
 9. The apparatus of claim 1, wherein each tube of the plurality of tubes includes a plurality of dimples, each dimple formed directly over one of the webs.
 10. An apparatus for transferring heat between a first fluid and second fluid in a motor vehicle, the apparatus comprising: a housing defining a chamber, the housing having a first inlet, a second inlet, a first outlet, and a second outlet; a first header separating a central portion of the chamber from a first header portion of the chamber, the first inlet and the first outlet in fluid communication with the central portion, the second inlet in communication with the first header portion; a second header separating the central portion of the chamber from a second header portion of the chamber, the second outlet in fluid communication with the second header portion; and a plurality of heat exchange tubes passing through the central portion of the chamber, each of the tubes having a first end in fluid communication with the first header portion, a second end in fluid communication with the second header portion; wherein each tube is defined in part by a pair of spaced apart sidewalls and further wherein each tube includes a plurality of internal webs extending between the respective spaced apart sidewalls.
 11. The apparatus of claim 10, wherein each tube of the plurality of tubes is generally rectangular in shape.
 12. The apparatus of claim 10, wherein the tubes are integrally extended to include the plurality of webs.
 13. The apparatus of claim 10, wherein the first end of each tube is brazed to the first header and the second end of each tube is brazed to the second header.
 14. The apparatus of claim 10, wherein each tube of the plurality of tubes defines a closed vessel for the transfer of fluid between the first and second header portions.
 15. The apparatus of claim 10, wherein each tube of the plurality of tubes includes a plurality of dimples, each dimple formed directly over one of the webs.
 16. An apparatus for transferring heat between a first fluid and second fluid in a motor vehicle, the apparatus comprising: a housing defining a chamber, the housing having a first inlet, a second inlet, a first outlet, and a second outlet; a first header separating a central portion of the chamber from a first header portion of the chamber, the first inlet and the first outlet in fluid communication with the central portion, the second inlet in communication with the first header portion; a second header separating the central portion of the chamber from a second header portion of the chamber, the second outlet in fluid communication with the second header portion; and a plurality of heat exchange tubes passing through the central portion of the chamber, each of the tubes having a first end in fluid communication with the first header portion, a second end in fluid communication with the second header portion; wherein each tube is defined in part by a pair of spaced apart sidewalls and further wherein each tube includes a plurality of internal webs extending between the respective spaced apart sidewalls; and wherein each tube further includes a plurality of dimples, each dimple formed directly over one of the webs.
 17. The apparatus of claim 16, wherein each dimple extends substantially between an adjacent web on either side of the one web.
 18. The apparatus of claim 16, wherein each dimple is a spherical depression stamped into one of the sidewalls.
 19. The apparatus of claim 16, wherein fluid in each of the tubes flows through triangular sections defined by the sidewalls, the dimples, and the webs. 